A recharging method and assembly to charge an electric vehicle comprising a battery pack including a plurality of storage batteries having a same nominal charge voltage, the battery pack being connectable to a recharging station adapted to provide a recharging voltage, which is greater than said nominal charge voltage. In a recharging mode, in which the recharging voltage deliverable by the recharging station is equal to or greater than the sum of the nominal charge voltages of the plurality of storage batteries, the storage batteries are connected in series to one another, so as to recharge the series of batteries with a recharging voltage greater than the nominal charge voltage.
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1. A method of recharging an electric vehicle (50) through a power supply and recharging assembly, the vehicle comprising a battery pack (2) including a plurality of storage batteries (2a, 2b, . . . , 2i, 2j) having a same nominal charge voltage, the battery pack (2) being connectable to a recharging station adapted to provide a recharging voltage,
the method comprising the steps of:
in a first recharging mode of the battery pack, in which the recharging voltage supplied by the recharging station is equal to said nominal charge voltage of the storage batteries, electrically connecting the storage batteries to the recharging station in parallel with each other, so as to recharge each storage battery with a recharging voltage equal to the nominal charge voltage; and
in a second recharging mode of the battery pack, in which the recharging voltage supplied by the recharging station is equal to sum of the nominal charge voltages of the plurality of storage batteries, electrically connecting the storage batteries in series to each other, so as to recharge the series of storage batteries with a recharging voltage equal to sum of the nominal charge voltages,
wherein said plurality of storage batteries includes a first and a second storage battery (2a, 2b) having said nominal charge voltage and each provided with a positive terminal (2a′, 2b′) and a negative terminal (2a″, 2b″);
and wherein the power supply and recharging assembly further includes:
first switching means comprising: a first switch (12a) coupled between the positive terminal (2a′) of the first storage battery (2a) and a positive voltage line (6a); a second switch (12b) connected between the negative terminal (2a″) of the first storage battery (2a) and a negative voltage line (6b); a third switch (14a) coupled between the positive terminal (2b′) of the second storage battery (2b) and the positive voltage line (6a); and a fourth switch (14b) coupled between the negative terminal (2b″) of the second storage battery (2b) and a negative voltage line (6b);
second switching means comprising: a fifth switch (16a) coupled between the first power supply terminal (4a) and the positive terminal (2a′) of the first storage battery (2a) and also coupled to the positive voltage line (6a) via said first switch (12a); and a sixth switch (16b) coupled between the second power supply terminal (4b) and the negative terminal (2b″) of the second storage battery (2b) and further coupled to the negative voltage line (6b); and
third switching means comprising: a series switch (20) coupled between the negative terminal (2a″) of the first storage battery (2a) and the positive terminal (2b′) of the second storage battery (2b),
the method further comprising:
in the first recharging mode of the battery pack (2), controlling in conduction the first, the second, the third, the fourth, the fifth and the sixth switches (12a-16b), and controlling in interdiction said series switch (20), to recharge the first and second storage batteries with a recharging voltage equal to the nominal charge voltage;
and, in the second recharging mode of the battery pack, controlling in interdiction the first, the second, the third and the fourth switches (12a-14b), and controlling in conduction said fifth and sixth switches (16a, 16b) and said series switch (20), so as to recharge the series of storage batteries with a recharging voltage higher than the nominal charge voltage.
4. A power supply and recharging assembly for an electric vehicle (50), comprising:
a battery pack (2) including a plurality of storage batteries (2a, 2b, . . . , 2i, 2j) having a nominal charge voltage, the battery pack (2) being connectable to a recharging station adapted to provide a recharging voltage;
a power bus (6) including a positive voltage line (6a) and a negative voltage line (6b); and
a connector (4), fixed to the electric vehicle, having a first and a second power supply terminal (4a, 4b) that are operatively coupled to the battery pack and to the power bus, configured to be connected to a recharging station that is adapted to supply said connector (4) with a recharging voltage;
the storage batteries of said plurality of storage batteries being coupled to the power bus, in a parallel electrical configuration, via first switching means (12a, 12b, 14a, 14b);
the storage batteries and the power bus being further coupled to the connector (4) via second switching means (16a, 16b); and
the storage batteries being further coupled in series with each other via a third switching means (20),
wherein, in a first recharging mode of the battery pack, in which the recharging voltage supplied by the recharging station is equal to said nominal charge voltage of the storage batteries, the first, the second and the third switching means are controllable to electrically connect said storage batteries in parallel with each other, so as to recharge each storage battery with a recharging voltage equal to the nominal charge voltage; and
in a second recharging mode of the battery pack, in which the recharging voltage supplied by the recharging station is equal to the sum of the nominal charge voltages of the plurality of storage batteries, the first, the second and the third switching means are controllable to electrically connect the storage batteries in series with each other, so as to recharge the series of storage batteries with a recharging voltage equal to the sum of the nominal charge voltages,
wherein said plurality of storage batteries includes a first and a second storage battery (2a, 2b) having said nominal charge voltage and each provided with a positive terminal (2a′, 2b′) and a negative terminal (2a″, 2b″);
wherein said first switching means comprise: a first switch (12a) coupled between the positive terminal (2a′) of the first storage battery (2a) and the positive voltage line (6a); a second switch (12b) connected between the negative terminal (2a″) of the first storage battery (2a) and the negative voltage line (6b); a third switch (14a) coupled between the positive terminal (2b′) of the second storage battery (2b) and the positive voltage line (6a); and a fourth switch (14b) coupled between the negative terminal (2b″) of the second storage battery (2b) and the negative voltage line (6b);
wherein said second switching means comprise: a fifth switch (16a) coupled between the first power supply terminal (4a) and the positive terminal (2a′) of the first storage battery (2a) and also coupled to the positive voltage line (6a) via said first switch (12a); and a sixth switch (16b) coupled between the second power supply terminal (4b) and the negative terminal (2b″) of the second storage battery (2b) and further coupled to the negative voltage line (6b); and
wherein said third switching means comprise a series switch (20) coupled between the negative terminal (2a″) of the first storage battery (2a) and the positive terminal (2b′) of the second storage battery (2b),
in the first recharging mode of the battery pack (2), the first, the second, the third, the fourth, the fifth and the sixth switches (12a-16b) are controllable in conduction and said series switch (20) is controllable in interdiction, to recharge the first and second storage batteries with a recharging voltage equal to the nominal charge voltage; and, in the second recharging mode of the battery pack, the first, the second, the third and the fourth switches (12a-14b) are controllable in interdiction, while said fifth and sixth switches (16a, 16b) and said series switch (20) are controllable in conducting, so as to recharge the series of storage batteries with a recharging voltage higher than the nominal charge voltage.
2. A battery-powered electric vehicle (50), including a power supply and recharging assembly according to
3. The electric vehicle (50) according to
5. The power supply and recharging assembly according to
6. The power supply and recharging assembly according to
acquire a maximum value for the recharging voltage deliverable by the recharging station;
implement the first battery pack recharging mode if the recharging voltage is lower than the sum of the nominal charge voltages of the plurality of storage batteries; and
implement the second battery pack recharging mode if the recharging voltage deliverable by the recharging station is equal to or greater than the sum of the nominal charge voltages of the plurality of storage batteries.
7. The power supply and recharging assembly according to
said first conduction terminal of said series switch (20) being coupled to the negative voltage line (6b) via the first switch (12b), and said second conduction terminal of said series switch (20) being coupled to the positive voltage line (6a) via the third switch (14a).
8. The power supply and recharging assembly according to
in a vehicle key-off operating mode, the first, the second, the third, the fourth, the fifth and the sixth switches are controllable in interdiction, so that the battery pack (2) is disconnected from both the connector (4) and the power bus (6); and
in a power delivery mode, the first, the second, the third and the fourth switches (12a-14b) are controllable in conduction state, while the fifth and the sixth switches (16a, 16b) and said series switch (20) are controllable in interdiction state, so that the battery pack (2) is connected to the power bus (6) to supply power to the power bus.
9. The power supply and recharging assembly according to
10. The power supply and recharging assembly according to
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This patent application claims priority from Italian patent application no. 102019000001099 filed on Jan. 24, 2019, the entire disclosure of which is incorporated herein by reference.
Not Applicable
The invention relates to a power supply and recharging assembly and method for an electric vehicle and to an electric vehicle comprising the power supply and recharging assembly.
As it is known, in an electric vehicle (EV), an electric motor is the only source of energy used to drive the vehicle; in a hybrid vehicle, the electric motor is an auxiliary source of energy added to the internal combustion engine.
In an electric vehicle, the energy powering the electric motor is typically stored in one or more storage batteries or batteries. When the energy stored in the batteries decreases, they can be charged by connecting to vehicle to an external power supply source. Recharging stations (also known as “Electric Vehicle Supply Equipment”—EVSE), which are used to this purpose, act as interfaces between the vehicle and a power supply network, in order to supply a charging or recharging current to the batteries. Known recharging stations are configured to deliver recharging powers whose maximum value depends on the voltage and current supported both by the recharging stations themselves and by the electrical components used to provide the service (cables, contacts, etc.). More in particular, the maximum deliverable voltage depends on the features, performances and/or building specifications of the recharging station taken into account and on the maximum voltage supported by the batteries of the electric vehicle being charged.
Currently, recharging stations are available, which are enabled to provide voltages up to 1000 V (high-power recharging stations—HPC EVSE) and ensure small charging times. However, in order to fully exploit the voltage provided by these stations, the batteries mounted on board the vehicle must be designed to support voltages with a corresponding value. Batteries capable of supporting recharging voltages up to 800 V are available in the market, but are very expensive and, therefore, are not widely spread.
Therefore, there is a strong need to make use of high-power recharging stations, in particular capable of delivering energy at 800 V, though using, at the same time, batteries that are available in the market and are not too expensive.
The object of the invention is to fulfil the needs discussed above.
The aforesaid object is reached by means of a power supply and recharging assembly and method for an electric vehicle and of an electric vehicle comprising the power supply and recharging assembly, as set forth in the appended claims
The invention will be best understood upon perusal of the following detailed description of a preferred embodiment, which is provided by way of non-limiting example, with reference to the accompanying drawings, wherein:
The electrical load 10 includes, in a per se known manner which is not part of the subject-matter of the invention, at least one inverter, which is coupled to the electric motor 10 so as to generate a torque to move the vehicle. The electrical load 10 can also include further components or systems of the electric vehicle, which use, for their operation, the current flowing in the power bus 6 (for example, the air conditioning system, the lighting system, the infotainment system, etc.).
The battery pack 2 comprises, in the embodiment of
The first storage battery 2a has a positive terminal 2a′ (terminal +) coupled to the positive voltage line 6a and a negative terminal 2a″ (terminal −) coupled to the negative voltage line 6b.
A switch 12a is interposed between the positive terminal 2a′ (terminal +) and the positive voltage line 6a. When the switch 12a is in an open state, the positive terminal 2a′ is electrically disconnected from the positive voltage line 6a; when the switch 12a is in a closed state, the positive terminal 2a′ is electrically connected to the positive voltage line 6a.
A switch 12b is interposed between the negative terminal 2a″ (terminal −) and the negative voltage line 6b.
When the switch 12b is in an open state, the negative terminal 2a″ is electrically disconnected from the negative voltage line 6b; when the switch 12b is in a closed state, the negative terminal 2a″ is electrically connected to the negative voltage line 6b.
Similarly, the second storage battery 2b has its own positive terminal 2b′ (terminal +) coupled to the positive voltage line 6a and its own negative terminal 2b″ (terminal −) coupled to the negative voltage line 6b.
A switch 14a is interposed between the positive terminal 2b′ (terminal +) and the positive voltage line 6a. When the switch 14a is in an open state, the positive terminal 2b′ is electrically disconnected from the positive voltage line 6a; when the switch 14a is in a closed state, the positive terminal 2b′ is electrically connected to the positive voltage line 6a.
A switch 14b is interposed between the negative terminal 2b″ (terminal −) and the negative voltage line 6b.
When the switch 14b is in an open state, the negative terminal 2b″ is electrically disconnected from the negative voltage line 6b; when the switch 14b is in a closed state, the negative terminal 2b″ is electrically connected to the negative voltage line 6b.
In
The first power supply pin 4a of the charging inlet 4 is coupled, through a switch 16a, to the node 15. The second power supply pin 4b is coupled, through a switch 16b, to the node 17.
The switches 16a and 16b can be switched to an open state and to a closed state so as to electrically disconnect and connect, respectively, the power supply pins 4a, 4b from/to the nodes 15, 17.
Therefore, according to the operating diagram suggested herein, the first power supply pin 4a of the charging inlet 4 is coupled to the positive power supply line 6a by means of the switch 12a and the second power supply pin 4b of the charging inlet 4 is coupled to the negative power supply line 6b by means of the switch 14b.
According to an aspect of the invention, the negative terminal 2a″ of the first storage battery 2a is coupled to the positive terminal 2b′ of the second storage battery 2b by means of a switch 20. The switch 20 can be switched to an open state so as to electrically disconnect the negative terminal 2a″ from the positive terminal 2b′ and to a closed state so as to electrically connect the negative terminal 2a″ to the positive terminal 2b′.
As explained more in detail below, the switch 20 has the function, in an operating condition which is better discussed hereinafter, of electrically connecting the first and the second storage batteries 2a, 2b to one another in series.
In a non-limiting embodiment, the switches 12a, 12b, 14a, 14b, 16a, 16b and 20 are contactors, namely electric-mechanical devices, which are not manually operated and are adapted to stand currents in high-power conditions (in this case, amounting to hundreds of Volts, in particular up to 800 V). Alternatively, the switches 12a, 12b, 14a, 14b, 16a, 16b and 20 can be solid-state devices, chosen depending on the needs.
The switches 12a, 12b, 14a, 14b, 16a, 16b and 20 are operatively coupled to an electronic control unit (shown in
In detail, the electronic control unit 51 is configured to control the switches 12a, 12b, 14a, 14b, 16a, 16b and 20 so as to implement a plurality of operating modes of the recharging circuit 1, among which there are, in particular: a rest mode (or “key-off” mode), a power supply mode, a first recharging mode and a second recharging mode.
In the key-off mode, the electric vehicle is not powered by means of the battery pack 2 and, at the same time, the battery pack 2 is not being charged (for example, when the electric vehicle is parked).
In the power supply mode, the electrical load 10 is powered by means of the battery pack 2 (for example, during the drive).
In the first and the second recharging modes, the batteries are charged using different values of recharging voltage.
The electronic control unit 51 can be the electronic control unit of the electric vehicle, properly configured, via software, to implement one or more of the aforesaid operating modes (in particular, the first recharging mode and the second recharging mode); alternatively, the electronic control unit 51 can be a further additional control unit beside the electronic control unit of the electric vehicle or a generic controller, properly configured and designed to implement one or more of the aforesaid operating modes (in particular, the first recharging mode and the second recharging mode).
More in detail, in the key-off mode, the switches 12a, 12b, 14a, 14b, 16a, 16b and, optionally, the switch 20 are controlled by the electronic control unit 51 so as to switch to an open state.
The following table schematically shows the state of the aforesaid switches in the key-off mode:
Switch 12a
OPEN
Switch 12b
OPEN
Switch 14a
OPEN
Switch 14b
OPEN
Switch 16a
OPEN
Switch 16b
OPEN
Switch 20
OPEN
Therefore, the batteries 2a and 2b are electrically disconnected both from the charging inlet 4 and from the power bus 6.
In the power supply mode, the switches 16a, 16b and 20 are controlled by the electronic control unit 51 so as to switch to an open state, whereas the switches 12a, 12b, 14a and 14b are controlled by the electronic control unit 51 so as to switch to a closed state.
The following table schematically shows the state of the aforesaid switches in the power supply mode:
Switch 12a
CLOSED
Switch 12b
CLOSED
Switch 14a
CLOSED
Switch 14b
CLOSED
Switch 16a
OPEN
Switch 16b
OPEN
Switch 20
OPEN
As a consequence, the batteries 2a, 2b are electrically connected in parallel to the power bus 6 and the electrical load 10 is powered by means of the voltage provided by the storage batteries 2a, 2b. As already mentioned above, in this embodiment, each storage battery 2a, 2b provides the power bus 6 with a nominal voltage of approximately 400V. Furthermore, the battery pack 2 is electrically disconnected from the charging inlet 4.
In the first recharging mode, the switch 20 is controlled by the electronic control unit 51 so as to switch to an open state, whereas the switches 16a, 16b, 12a, 12b, 14a and 14b are controlled by the electronic control unit 51 so as to switch to a closed state.
The following table schematically shows the state of the aforesaid switches in the first recharging mode:
Switch 12a
CLOSED
Switch 12b
CLOSED
Switch 14a
CLOSED
Switch 14b
CLOSED
Switch 16a
CLOSED
Switch 16b
CLOSED
Switch 20
OPEN
As a consequence, the first and the second storage batteries 2a, 2b are electrically connected to one another in parallel and are charged by means of the power supply voltage provided by the charging station through the charging inlet 4. In a known manner, during the first recharging mode, the electric vehicle communicates to the recharging station the maximum voltage limit supported by the battery pack 2, so as to protect the battery pack 2 from overvoltages. In this way, even though the known recharging station can supply voltages up to 1000V (more commonly 800V), the battery pack 2 is charged at the nominal charge voltage of the storage batteries 2a, 2b, without damages. Since the power bus 6 is powered, the electrical load 10 can be selectively disconnected from the power bus 6.
In the second recharging mode, the switches 16a, 16b and 20 are controlled by the electronic control unit 51 so as to switch to a closed state, whereas the switches 12a, 12b, 14a and 14b are controlled by the electronic control unit 51 so as to switch to an open state.
The following table schematically shows the state of the aforesaid switches in the second recharging mode:
Switch 12a
OPEN
Switch 12b
OPEN
Switch 14a
OPEN
Switch 14b
OPEN
Switch 16a
CLOSED
Switch 16b
CLOSED
Switch 20
CLOSED
As a consequence, the first and the second storage batteries 2a, 2b are electrically connected to one another in series and are charged by means of the power supply voltage provided by the charging station through the charging inlet 4.
During the first and the second recharging modes, the electric vehicle communicates to the recharging station, through the battery management system—BMS, the maximum voltage supported by the battery pack 2. The BMS communicates with the recharging station through high-level communication (e.g. PLC or WiFi or another communication mode), according to the IEC61851 and ISO 15118 standards. The BMS is also interfaced with the electronic control unit 51 and serves as communication interface between the latter and the recharging station.
As an alternative or in addition to the BMS, the VMU can carry out this interface function.
Since the storage batteries 2a, 2b are electrically connected to one another in series, the maximum voltage supported by the battery pack 2, in the second recharging mode, is greater than each one of the nominal voltages of the storage batteries 2a, 2b; in particular, the maximum voltage supported by the battery pack 2 is the result of the sum of the nominal charge voltages of the storage batteries 2a, 2b (hence, in this example, the maximum voltage supported by the battery pack 2 is 800V). In this way, the potentialities of the recharging station (for instance, power delivered) can be exploited to the utmost, charging the battery pack 2 at a voltage that is greater than the one of the recharging mode described above, thus reducing charging times.
Based on the information received from the BMS, depending on the voltage that can be delivered by the recharging station, the electronic control unit 51 controls the state of the switches 12a, 12b, 14a, 14b, 16a, 16b and 20, implementing one of the recharging modes of the battery pack 2 described above based on the electric features of the recharging station with which the recharging circuit 1 is interfaced. For example, the switches are controlled in accordance with the first recharging mode (batteries 2a, 2b in parallel) in order to charge the batteries 2a, 2b at 400V when the recharging station supports a maximum voltage of 400V, or in accordance with the second recharging mode (batteries 2a, 2b in series) in order to charge them at 800V when the recharging station supports a maximum voltage of 800V.
According to a further embodiment, which is shown in
The nominal charge voltage of the storage batteries 2a-2j is chosen during the design phase based on the maximum voltage that can be delivered by the existing recharging stations and on the number of storage batteries to be installed on board the vehicle. In particular, the storage batteries 2a-2j have a same nominal charge voltage, which is chosen in such a way that the sum of the nominal charge voltages of the storage batteries 2a-2j (namely, the charge voltage at the ends of the battery pack 2 when the storage batteries 2a-2j are arranged in series with one another) is equal to or smaller than the voltage that can be delivered by the recharging station. In the diagram of
In order to create the electric series connection of the storage batteries 2a-2j, there are switches 20a, 20i and 20j that electrically connect the opposite terminals of successive storage batteries of the electric series, similarly to what described above with reference to the switch 20, so as to obtain a series connection of all the storage batteries 2a-2j of the battery pack 2.
Furthermore, the switches 22a, 22b, 24a and 24b are shown, which have a function that is similar to the one described in
As a consequence, when the storage batteries 2a-2j are charged in accordance with the second recharging mode described above, the storage batteries 2a-2j are arranged in series with one another closing the switches 20a, . . . , 20i, 20j; therefore, they can be charged exploiting the maximum voltage delivered by the recharging station.
According to a further embodiment, which is shown in
Owing to the above, the advantages of the subject-matter of the invention are evident.
In particular, the invention allows for a reduction of the time needed to charge the battery pack of the electric vehicle, with the possibility of adjusting to the features and performances of different recharging stations with which the electric vehicle can be interfaced during the use, using low-cost components. In particular, it is possible to use batteries with a nominal charge voltage of a few or some hundreds of Volts (for example, up to 400V), which can easily be found in the market and are relatively cheap, and, at the same time, it is possible to fully exploit the power that can be delivered by high-power recharging stations (HPC EVSE), which are designed to supply power with voltages up to 800-1000V.
Finally, the subject-matter of the invention can be subjected to changes and variants, which, though, do not go beyond the scope of protection set forth in the appended claims.
For example, one or more of the switches 12a, 12b, 14a, 14b, 16a, 16b and 20 can be arranged in a different way than the one shown in the figures, provided that they implement, when they are controlled accordingly, the operating modes provided for by the invention (in particular, the shift from the first to the second recharging mode depending on the voltage than can be delivered by the recharging station).
Mantovani, Giorgio, Bernardini, Alessandro, Bertolotto, Cristian, Zappaterra, Massimo
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